Do you need to push your thermal performance to its limits and explore all your options?

The electric vehicle industry is an example of innovation. Engineers often face challenges in the battery pack. The battery management system is a separate application that requires effective thermal management solutions. 

Also, there is a massive spike in demand for EVs in the automotive market. As a result, several materials and solutions are used as thermal interface materials, and that is all we will discuss in this blog. 

So, The First Question Is What Is Electric Vehicle Thermal Management?

Electric vehicles run on electricity which is stored in the batteries. The battery is made of several battery cells that are stacked together. These battery cells contain all the power required for the EV. In addition, the battery cells generate heat when a battery is charged and discharged. 

The excessive heat is damaging to the battery cells and other components too. Thermal management solutions for electric vehicles help reduce the heat and slow the heat generation process.

Effective thermal management systems keep the temperature within the ideal range. The control of temperature ensures the safety of the EV. It also provides an extended life cycle and optimal energy efficiency. 

The heat exposure time and temperature are regularly monitored. The thermal management solutions for electric vehicles have hydrolysis resistance. Electric vehicle thermal management is a much longer process. The battery pack temperature is managed, and the temperature range is narrow. The cold temperature also requires management when it is charged or parked in a cold climate or temperature.

The EV lithium-ion battery technology gives performance and range. In addition, lithium-ion batteries are lighter than other batteries, such as lead-acid and nickel metal.

The batteries’ heat flow inside the vehicle, and the components must be in the exemplary operating temperature range. Therefore, EV thermal management is much more conventional. 

What components are used in thermal management solutions for electric vehicles?

An electric vehicle has several applications running. As a result, several aspects of EVs need special attention, and each of them requires distinct components and products to enable that action.

Taking Electric Vehicle Thermal Management To The Next Level

The first application of EV we will discuss is thermal management of the battery pack. The battery management system is vast and thermal management is just one tinny aspect of it. 

For the thermal management system of the battery pack, several components can be used. For example, EV battery manufacturing companies use 3M Novec engineered fluids. These are also known as immersion cooling liquids for EV batteries. 

For example, 3M Novec 7100 provides excel in heat transfer application for an EV battery. It is effective at a wide range of temperatures and has excellent material compatibility that avoids damage to the equipment. In addition, it has high dielectric strength, making it safer for other electrical components in the EV battery.

Similarly, Novec 7500, Novec 7000, and Novec 7300 are some of the other exemplary engineered fluids from 3M. These are also used for immersion cooling and can be chosen based on different factors of the applications. In addition, these are non-flammable, ideally in sync with the requirement. 

Bonding Solutions

The battery pack requires high-strength bonding to keep all the components together. For this, we recommend using 3M thermally conductive tapes, e.g., 8805, 8810, 8815, 8820, 5413, and 7413D. These high bonding tapes can work under immense pressure and varying temperatures. 

3M VHB tapes like 5925, 5915, 5930, 5962, 5952, and 5962 can withstand high heat, which makes them an ideal bonding solution for EV batteries. Some of the 3M tapes can bond different substrates and can be used to bond the box which contains the battery and components. You can reduce the weight of the battery box by eliminating metal screws and rivets. 

Their replacement tapes are much lighter and come in various thicknesses and sizes. These are highly capable of keeping the layers together for a longer time.

Cushioning And Insulating The Battery Pack

The battery pack is made of several individual battery cells stacked together. Therefore, external factors will likely impact the internal components of the battery. To prevent this, 3M electronic grade coatings like Novec 1700 and Novec 2704 are best. They create a barrier or layer. The layer prevents moisture or dirt from entering the battery pack. 

Insulation is also required to prevent current leakage. 3M tapes are also an excellent option for insulation. You can use these tapes for also cushioning, which will protect the battery from external damage.

Thermally conductive pads 5514, 5519, and 5595 are very effective in dampening external shock and vibration.

3M Thermally Conductive Gap Fillers such as TC 3500, TC 7000, and TC 4000 are used to fill the gaps between 2 components. The black space can accumulate and hold heat. Thermally conductive gap pads will improve heat resistance and provide shock absorption.0020

What Are The Benefits Of Electric Vehicle Thermal Management?

There are many system benefits for the manufacturers as well as the drivers. The EV system engineers and manufacturers get a higher range and lower energy consumption—the development of innovative products that are compatible with the future requirements of the EV industry. 

Also, thermal management provides high system competence to EVs and provides a holistic simulation. 

For drivers, it gives lower energy consumption hence the higher range. It provides very comfortably cooling and heating inside the vehicle. For the vehicle’s driver, the reliability must always be intact and available throughout the year. The changing climate shouldn’t impact it. Fast charging is one of the best features for drivers. They can get the maximum output with a shorter time of charging. 

Conclusion 

Electric cars are an alternative to traditional fuel-based cars. EVs are efficient and also consume less energy. They run on electrically charged batteries and provide environment-friendly automobiles. 

Yet the EVs have one significant aspect that faces challenges: the battery management system. Electric vehicle thermal management is the biggest concern of EV manufacturing companies. 

E Control Devices is a company working with leading EV manufacturers. We have a variety of EV solutions like circuit protection, battery management system, and many others. You can visit our website www.econtroldevices.com to view our EV catalog and share your query.